Concrete forming system

ABSTRACT

A concrete forming system includes a plurality of panels, an inside corner form, an outside corner form and a plurality of fasteners for securing the panels and forms together.

This application is a continuation of U.S. provisional patentapplication Ser. No. 60/758,820, filed Jan. 13, 2006, which is herebyincorporated by reference in its entirety.

TECHNICAL FIELD

The present invention relates generally to the construction field and,more particularly, to a system for forming poured concrete.

BACKGROUND OF THE INVENTION

Over the years, many different systems have been utilized to formconcrete. Examples of such systems are found in U.S. Pat. Nos. 6,916,001to Pugh, Jr. and 4,006,878 to Dawson et al. The present inventionrelates to a new and improved lightweight concrete forming system thatadvantageously utilizes reusable components and provides for the formingof precise corners in a quick and efficient manner.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as describedherein, a concrete forming system is provided. The concrete formingsystem includes a plurality of panels, an inside corner form, an outsidecorner form and a plurality of fasteners for securing the panels and theforms together. Each of the panels includes a wall having a concreteforming surface, a recessed margin and a projecting margin. The recessedmargin is provided along the first and third edges of the panel whilethe projecting margin is provided along the second and fourth edges ofthe panel. Reinforcing ribs are provided to support the concrete formingsurface and the recessed margin.

The projecting margin has a thickness A and the recessed margin isrecessed from the concrete forming surface by the same distance A. Theprojecting margin also has a width B and the recessed margin has anidentical width B. The projecting margin on one panel effectively mateswith the recessed margin on a second panel so that the panelseffectively interlock and join with overlapping edges that provide asmooth concrete forming surface.

The inside corner form includes a first side wall, a second side walland a gusset wall connecting the first and second side walls. Similarly,the outside corner form includes a first side wall, a second side walland a gusset wall connecting the first and second side walls. Further,both the inside corner form and the outside corner form includereinforcing ribs to structurally support the corner forms when subjectedto the weight and pressure of poured concrete during the formingprocess. The inside corner form and outside corner form also includerecessed margins and projecting margins to allow them to mate andinterlock with similar cooperating structures provided on the panels.

Adjacent panels and corner forms may be secured together by fastenersthat comprise resilient clips. Specifically, the reinforcing ribs on thepanels and corner forms are engaged by the fasteners to secure thecomponents together. Each resilient clip includes a head and a pair ofcooperating lugs defining a fastening channel. Each of the cooperatinglugs may include fastening teeth to help secure the clips in positionover the reinforcing ribs.

The concrete forming system also includes a plurality of walers whichfunction as vertical and horizontal supports for the panels and cornerforms of the concrete forming system. Still further, the concreteforming system includes a series of corner plates. Each corner plateincludes a first side wall, a second side wall and a gusset wallconnecting the first and second side walls. The corner plates furtherinclude a tie aperture in the gusset wall.

Each of the panels and corner forms also includes a tie aperture. Thetie apertures in opposing panels and corner forms of the concreteforming system are aligned and receive steel ties of a type known in theart. These steel ties run between the opposing panels and corner formsand also extend through and beyond the supporting walers along thepanels and through and beyond the tie aperture of the corner plates. Bytightening wedges it is possible to maintain the panels and corner formsof the forming system parallel and a fixed distance apart.

The panels and corner forms may be constructed from a fiber reinforcedpolymer. The fiber reinforced polymer may include glass fibers and apolyolefin such as polypropylene. The panels and corner forms may usevirgin and/or recycled materials.

In the following description there is shown and described one possibleembodiment of this invention, simply by way of illustration of one ofthe modes best suited to carry out the invention. As it will berealized, the invention is capable of other different embodiments andits several details are capable of modification in various, obviousaspects all without departing from the invention. Accordingly, thedrawings and descriptions will be regarded as illustrative in nature andnot as restrictive.

BRIEF DESCRIPTION OF THE DRAWING

The accompanying drawing incorporated in and forming a part of thespecification, illustrates several aspects of the present invention andtogether with the description serves to explain certain principles ofthe invention. In the drawing:

FIG. 1 a is a front perspective view illustrating an outside corner ofthe concrete forming assembly of the present invention;

FIG. 1 b is a rear perspective view of the assembly shown in FIG. 1 aillustrating the inside corner;

FIG. 2 a is a front perspective view of a panel used in the concreteforming assembly to form straight walls of poured concrete;

FIG. 2 b is a rear perspective view of the panel illustrated in FIG. 2a;

FIG. 3 is a detailed cross sectional view illustrating how two adjacentpanels interlock with overlapping edges;

FIG. 4 is a rear perspective view of an inside corner form;

FIG. 5 is a rear perspective view of an outside corner form;

FIG. 6 a is a front perspective view of a corner plate;

FIG. 6 b is a cross sectional view of the corner plate of FIG. 6 aillustrating the inclined mounting track;

FIG. 7 is a perspective view of the resilient clip utilized to fastenthe panels and corner forms together;

FIG. 8 a is a detailed cross sectional view through a complete concreteform of a straight wall showing how a steel tie extends through theforming assembly holding the poured concrete;

FIG. 8 b is a detailed cross sectional view through a complete concreteform of a corner showing how a steel tie extends through the formingassembly holding the poured concrete; and

FIG. 9 is a perspective view of a wedge used to lock the panels andcorner forms in position over steel ties.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to FIGS. 1 a and 1 b illustrating the concreteforming system 10 of the present invention. As illustrated in thesefigures, the system 10 is being utilized to form two walls and a cornerof a building foundation from poured concrete. Specifically, a series ofstraight wall panels 12, inside corner forms 14 and outside corner form16 are held together by fasteners 58 and structurally supported by aseries of walers 68,70 and corner plates 72 as will be described ingreater detail below.

As illustrated in FIGS. 2 a and 2 b each panel 12 includes a wall 24having a concrete forming surface 26, a recessed margin 28 and aprojecting margin 30. The recessed margin 28 is provided along at leasta first edge of the wall 24 and the projecting margin 30 is providedalong at least the second, opposite edge. In another possible embodimentand as illustrated, the recessed margin 28 is provided along the firstand third edges of the wall 24 that form a first corner. Similarly, theprojecting margin 30 is provided along the second and fourth edges ofthe wall that form a second, opposite corner.

A series of reinforcing ribs 32 support the concrete forming surface 26and the recessed margin 28. As illustrated the projecting margin 30 hasa thickness A and the recessed margin 28 is recessed from the concreteforming surface 26 by the same distance A. Further, both the projectingmargin 30 and recessed margin 28 have a width B.

This structural arrangement of the recessed and projecting margins 28,30 allows the panels 12 to be interlocked: that is, the projectingmargin 30 of a first panel 12 mates or nests with and is received in therecessed margin 28 of a second panel 12 so that a continuous concreteforming surface 26 is provided by the adjacent panels (note particularlyFIGS. 3 and 8 a). Where each panel 12 includes recessed margins 28 alongthe first and third edges and projecting margins 30 along the second andfourth edges, overlapping joints may be provided between panels in twoperpendicular directions (i.e. horizontally and vertically).

As illustrated in FIG. 4, each inside corner form 14 includes a firstside wall 34, a second side wall 36 and a gusset wall 38 connecting thefirst and second side walls. The first side wall 34 includes a recessedmargin 40 identical in dimension to the recessed margin 28 along atleast one and preferably two edges (i.e. with a recessed distance A anda width B). The recessed margin 40 also extends across one end of thegusset wall 38. The second side wall 36 includes a projecting margin 42identical in size and shape to the projecting margin 30 along at leastone and preferably two edges (i.e. with a thickness A and a width B).The projecting margin also extends across one end of the gusset wall 38.A series of reinforcing ribs 44 are provided to support the first sidewall 34, second side wall 36 and gusset wall 38 everywhere except behindthe projecting margin 42. This structural arrangement allows therecessed margin 40 of the inside corner form 14 to mate and interlockwith the projecting margin 30 of a panel 12 and the projecting margin 42of the inside corner form to mate and interlock with the recessed margin28 of a panel 12 in the same manner as illustrated in FIG. 3.Accordingly, a smooth continuous concrete forming surface 26 is providedalong an interior wall fully around a corner to a second interior wallutilizing the concrete forming system 10 of the present invention (seealso FIG. 8 b).

As illustrated in FIG. 5, the outside corner form 16 includes a firstside wall 48, second side wall 50 and gusset wall 52 for connecting thefirst and second side walls 48, 50. The first side wall 48 includes arecessed margin 54 along at least one and preferably two edges (with arecessed distance A and a width B) while the second side wall 50includes a projecting margin 56 along at least one and preferably twoedges (with a thickness A and a width B). The recessed margin 54 alsoextends across one end of the gusset wall 52 (hidden from view in FIG.5). Similarly, the projecting margin 56 also extends across the oppositeend of the gusset wall 52 (hidden from view in FIG. 5). Reinforcing ribs57 are provided to support the walls 48, 50 and 52 everywhere exceptbehind the projecting margin 56. These margins 54, 56 function to mateand interlock with cooperating margins on the panels 12 in the samemanner described above with respect to the inside corner form 14. Theonly difference is the outside corner form 16 and adjacent panels 12function to provide a smooth, continuous concrete surface 26 about theoutside corner of two walls of poured concrete (see also FIG. 8 b).

As illustrated in FIG. 1 a, various panels 12 and inside corner forms 14are arranged in position together in order to form an inner wall formingassembly 100. The illustrated inner wall assembly 100 is constructedfrom panels 12 and corner forms 14, 16 that are four feet in height.Thus, two such panels 12 and corner forms 14, 16 are stacked to providea wall eight feet in height. The inner wall assembly 100 provides asmooth concrete forming surface 26 for the interior of a poured concretefoundation. Fasteners in the form of resilient clips 58 are utilized tosecure adjacent panels 12 and inside corner forms 14 together. Asillustrated in FIG. 7 each resilient fastener 58 includes a head 60 witha reinforcing rib 63 and a pair of cooperating lugs 62 that define afastening channel 64. One or both of the lugs 62 may be provided withfastening teeth 66 to aid in maintaining the clips 58 in engagement withjuxtaposed reinforcing ribs 32, 44 or 57 of the adjacent panels 12 andcorner forms 14, 16.

As illustrated in FIG. 1 b, various panels 12 and outside corner forms16 are positioned together to form an outer wall forming assembly 200 toprovide a continuous concrete forming surface 26 for the exterior faceof the poured concrete foundation. More specifically, the panels 12 andoutside corner forms 16 of the outer wall forming assembly 200 arepositioned a desired distance from the panels 12 and inside corner forms14 of the inner wall forming assembly 100. Clips 58 are used to hold thepanels 12 and outer corner forms 16 together. The space or gap G betweenthe continuous concrete forming surfaces 26 of the inner and outer wallsforming assemblies 100, 200 is provided to receive the poured concrete.

It should be appreciated that poured concrete is quite heavy andsignificant pressure is placed upon the panels 12 and corner forms 14,16 during wall construction. Horizontal walers 68, vertical walers 70,corner plates 72 and wedges 74 are utilized to reinforce the inner andouter wall forming portions of the concrete forming system 10 againstthese forces.

More specifically, as illustrated in FIGS. 2 a, 2 b, 4 and 5 tieapertures 76 are provided at spaced locations along the panels 12,inside corner forms 14 and outside corner forms 16. As the inner andouter wall forming assemblies 100, 200 are built from the panels 12,inside corner forms 14 and outside corner forms 16, these tie apertures76 are aligned across the gap G between the assemblies. Steel ties T, ofa type well known in the art with an elongated body and an enlarged headH at each end, are positioned through these aligned tie apertures 76 soas to extend across the gap G and project outwardly from the cooperatingpanels 12, inside corner forms 14 and outside corner forms 16.

Next, the horizontal walers 68 are positioned along the outer side ofthe panels 12, inside corner forms 14 and outside corner forms 16 (i.e.the reinforcing rib side). Specifically, the walers 68 include aperturesthat are received over the steel ties T. Next, vertical walers 70 areprovided over the horizontal walers 68 in order to provide additionalrigidity and support to the inner and outer wall forming assemblies 100,200. As illustrated in FIG. 1 a, two vertical walers 70 are provided onthe outer wall forming assembly 200 adjacent the corner thereof.Specifically, each vertical waler 70 also includes spaced apertures thatare received over the steel ties T projecting from the apertures in thehorizontal walers 68.

Wedges 74 of a type known in the art are then positioned over the steelties T along the inner and outer wall forming assemblies 100, 200. Morespecifically, each wedge 74 includes an enlarged aperture 80 at one endof an inclined mounting track 81 including an elongated slot 82. Theenlarged aperture 80 is of sufficient diameter to allow the head H atthe end of a steel tie T to pass. The wedge 74 is then shifted laterallyso that the steel tie T is received in the inclined slot 82. Theinclined slot 82 is dimensioned to allow free sliding movement of themain body of the steel tie T but will not allow passage of the head H.By sliding a wedge 74 laterally until the head H firmly engages the topof the wedge it is possible to secure the inner and outer wall formingassemblies 100, 200 together and provide a gap G between the assembliesof consistent dimension all along the straight walls and through thecorners. Specifically, wedges 74 are tightened against the heads H ateach end of a tie T to complete the fabrication of the system 10 (seeparticularly FIG. 8 a). In FIG. 8 b, the vertical walers 70 and wedges74 have not yet been installed over the steel ties T along the innerassembly 100.

As further illustrated in FIGS. 1 a, 1 b and 8 b, the corners may befurther reinforced with reversible corner plates 72. Each corner plate72 includes a first wall 86, a second wall 88 and a gusset wall 90connecting the first and second walls 86, 88 (see FIGS. 6 a and 6 b).Each gusset wall 90 includes an aperture 92 for receiving a steel tie T.

As illustrated in FIG. 1 a, the corner plates 72 are positioned alongthe inside corners of the inside corner forms 14 with the first andsecond walls 86, 88 thereof overlying the ends of the horizontal walers68. As illustrated in FIG. 1 b, the corner plates 72 are oriented inreverse and positioned over the outer corner of the outside corner forms16 with the first and second walls 86, 88 thereof overlying thehorizontal walers 68. During this positioning process the head H of thecooperating steel tie T is inserted through the aperture 92 in thecorner plate 72. A wedge 74 is then used to snug the assembly together.More specifically, the head H of the tie T is inserted through the largeaperture 80. Next, the wedge 74 is shifted laterally until the head Hfirmly engages the top of the wedge. By tightening the corner plates 72on each side of the system 10 with wedges 74 in this fashion, theassemblies 100, 200 are made ready for the pouring of concrete. Itshould be appreciated that the concrete forming system 10 of the presentinvention allows the use of steel ties T in the corners as well as alongthe straight walls to better insure the pouring of a concrete wall ofconsistent thickness.

In accordance with an additional aspect of the present invention, thepanels 12, the inside corner forms 14 and the outside corner form 16 mayall be constructed from a fiber reinforced polymer. Specifically, thesecomponents 12, 14 and 16 may be molded from fiber reinforced polymerincluding, for example, glass fibers and a polyolefin such aspolypropylene. In fact, recycled glass fibers and/or polyolefin may beutilized. Advantageously, panels 12, inner corner forms 14 and outercorner forms 16 constructed from such a material provide a smooth,olefin-rich concrete forming surface 26 that does not stick to concretethereby eliminating the need to use oil or release compounds. The panels12, inside corner forms 14 and outside corner forms 16 made from thismaterial are also reusable. Further, they are light in weight, evenlighter than aluminum and, accordingly, are very easy to use. The walers68, 70 may also be formed from fiber reinforced polymer as a pultrusion.Thus, the walers 68, 70 may also be made lightweight and reusable. Inthe alternative, the walers 68, 70 may be made from wood, a composite orother appropriate materials.

The foregoing description of a preferred embodiment of the presentinvention has been presented for purposes of illustration anddescription. It is not intended to be exhaustive or to limit theinvention to the precise form disclosed. Obvious modifications orvariations are possible in light of the above teachings. For example,while the panels 12 and the corner forms 14, 16 illustrated anddescribed in FIG. 1 a are four feet in height, they could be made of anysize including, for example, in heights of eight, nine and ten feet.Further, the panels 12 may be made of substantially any width (e.g. six,eight or ten inches) as well so that they may be pieced together to makea wall of substantially any desired length. A typical panel 12 used inthe system 10 may, for example, be eight feet by two feet in dimension.In addition, while a smooth concrete forming face 26 has beenillustrated and described, it should be appreciated that the face may betextured if desired to provide the concrete with, for example, a brickor sandstone surface appearance.

The embodiment was chosen and described to provide the best illustrationof the principles of the invention and its practical application tothereby enable one of ordinary skill in the art to utilize the inventionin various embodiments and with various modifications as are suited tothe particular use contemplated. All such modifications and variationsare within the scope of the invention as determined by the appendedclaims when interpreted in accordance with the breadth to which they arefairly, legally and equitably entitled. The drawings and preferredembodiments do not and are not intended to limit the ordinary meaning ofthe claims and their fair and broad interpretation in any way.

1. A concrete forming system, comprising: a plurality of interlockingpanels; an inside corner form; an outside corner form; and a pluralityof fasteners for securing said panels and forms together.
 2. The systemof claim 1, wherein each panel of said plurality of panels includes (a)a wall having a concrete forming surface, a recessed margin along afirst edge of said wall and a projecting margin along a second, oppositeedge of said wall and (b) reinforcing ribs supporting said concreteforming surface and said recessed margin.
 3. The system of claim 2,wherein said projecting margin has a thickness A and said recessedmargin is recessed from said concrete forming surface by a distance A.4. The system of claim 3, wherein said projecting margin has a width Band said recessed margin has a width B.
 5. The system of claim 4,wherein each panel of said plurality of panels includes at least one tieaperture.
 6. The system of claim 5 wherein said recessed margin is alsoprovided along a third edge of said panel and said projecting margin isalso provided along a fourth edge of said panel.
 7. The system of claim1, wherein said inside corner form includes a first side wall, a secondside wall, a gusset wall connecting said first and second side walls andreinforcing ribs.
 8. The system of claim 7, wherein said first side wallincludes a recessed margin, said second side wall includes a projectingmargin and said inside corner form includes at least one tie aperture.9. The system of claim 8, wherein said at least one tie aperture isprovided in said gusset wall.
 10. The system of claim 9, wherein saidrecessed margin is provided along two edges of said first side wall andsaid projecting margin is provided along two edges of said second sidewall.
 11. The system of claim 1, wherein said outside corner formincludes a first side wall, a second side wall, a gusset wall connectingsaid first and second side walls and reinforcing ribs.
 12. The system ofclaim 11, wherein said first side wall includes a recessed margin, saidsecond side wall includes a projecting margin and said outside cornerform includes at least one tie aperture.
 13. The system of claim 12,wherein said at least one tie aperture is provided in said gusset wall.14. The system of claim 13, wherein said recessed margin is providedalong two edges of said first side wall and said projecting margin isprovided along two edges of said second side wall.
 15. The system ofclaim 1, wherein said each fastener of said plurality of fastenerscomprises a resilient clip.
 16. The system of claim 15, wherein saidresilient clip includes a head and a pair of cooperating lugs defining afastening channel.
 17. The system of claim 16, wherein said pair ofcooperating lugs include fastening teeth.
 18. The system of claim 1,wherein said system further includes a corner plate including a firstside wall, a second side wall and a gusset wall connecting said firstand second side wall.
 19. The system of claim 18, wherein a tie apertureis provided in said gusset wall.
 20. The system of claim 19, whereinsaid system further includes a plurality of walers.
 21. The system ofclaim 1, wherein said plurality of interlocking panels and corner formsare constructed from a fiber reinforced polymer.
 22. The system of claim21 wherein said fiber reinforced polymer includes glass fibers and apolyolefin.
 23. The system of claim 22, wherein said polyolefin ispolypropylene.
 24. The system of claim 22, wherein said polyolefin isrecycled polyolefin.
 25. A concrete forming element, comprising: a panelincluding (a) a wall having a concrete forming surface, a recessedmargin at a first side of said wall and a projecting margin at a secondside of said wall and (b) reinforcing ribs supporting said concreteforming surface and said recessed margin.
 26. The concrete formingelement of claim 25, wherein said projecting margin has a thickness Aand said recessed margin is recessed from said concrete forming surfaceby a distance A.
 27. The concrete forming element of claim 26, whereinsaid projecting margin has a width B and said recessed margin has awidth B.
 28. The concrete forming element of claim 27, further includingat least one tie aperture.
 29. A concrete forming element, comprising:an inside corner form including a first side wall, a second side wall, agusset wall connecting said first and second side walls and reinforcingribs.
 30. The concrete forming element of claim 29 further including atleast one tie aperture in said gusset wall.
 31. A concrete formingelement, comprising: an outside corner form including a first side wall,a second side wall, a gusset wall connecting said first and second sidewalls and reinforcing ribs.
 32. The concrete forming element of claim 31further including at least one tie aperture in said gusset wall.
 33. Acorner plate for a concrete form, comprising: a first side wall; asecond side wall; a gusset wall connecting said first and second sidewalls; and an aperture in said gusset wall.